MIcro Pump Systems and Processing Techniques

ABSTRACT

Disclosed is a valve-less micro pump configuration that includes plural micro pump elements, each including a pump body having a compartmentalized pump chamber, with plural unobstructed inlet ports and outlet ports and a plurality of membranes disposed in the pump chamber to provide compartments. The membranes are anchored between opposing walls of the pump body and carry electrodes disposed on opposing surfaces of the membranes and walls of the pump body.

CLAIM OF PRIORITY

This application claims priority under 35 U.S.C. § 119(e) to provisionalU.S. Patent Application 62/470,460, filed on Mar. 13, 2017, entitled:“Micro Pump Systems and Processing Techniques” the entire contents ofwhich are hereby incorporated by reference.

BACKGROUND

This specification relates to micro-based systems and more particularlyto micro pump systems/devices.

Mechanical pump systems and compressor systems are well-known. Pumps areused to move fluid (such as liquids or gases or slurries) by mechanicalaction. Pumps can be classified according to the method used to move thefluid, e.g., a direct lift pump, a displacement pump, a peristalticpump, and a gravity pump. Micro pumps are now also known. One example ofa micro pump is described in my published applicationUS-2015-0267695-A1, published Sep. 24, 2015 filed Feb. 26, 2015 theentire contents of which are incorporated herein by reference.Techniques for fabricating such micro pumps are also disclosed in theabove mentioned published application. Also disclosed in my publishedapplication US-2016-0131126-A1, published May 12, 2016 and filed Oct.29, 2015 the entire contents of which are incorporated herein byreference, are additional micro pump examples, exemplary applicationsand microelectromechanical systems (MEMS) fabrication techniquesincluding roll to roll processing.

SUMMARY

Described are peristaltic micro pump systems. Exemplary techniques tofabricate such peristaltic micro pump systems include using lithographicetching and patterning techniques as well as roll to roll fabricationtechniques.

The described peristaltic micro pump systems are provided by cascadeconnecting individual micro pump units. These units do not includeinternal, fixed inlet and outlet valve members/structures such as thosedisclosed in the above applications. By operating the individual micropump units in a phased sequence, such operation can effectively provideinlet and outlet isolation functions, thus obviating the need for fixedinternal inlet valve structures and outlet valve structures.

According to an aspect, a micro pump includes a plurality of micro pumpelements, each micro pump element including a pump body having wallsthat enclose a pump chamber that is compartmentalized into pluralcompartments, a plurality of inlet ports each with unobstructed fluidingress into corresponding ones of the plural compartments and aplurality of outlet ports each with unobstructed fluid egress fromcorresponding ones of the plural compartments, a plurality of membranesdisposed in the pump chamber, with the plurality of membranes affixed tothe walls of the pump body, and which compartmentalized the chamber toprovide the plural compartments, and a plurality of electrodes, with afirst pair of the plurality of electrodes disposed on a pair of opposingwalls of the pump body, and each of the remaining ones of the pluralityof electrodes disposed on a major surface of a corresponding one of theplurality of membranes, with the plurality of micro pump elementsarranged in a series connected configuration that has outlets of a firstone of the plurality of micro pump elements fluidly connected to inletsof an immediately adjacent one of the plurality of micro pump elements.

Other aspects include methods of manufacture and methods of use.

The details of one or more embodiments of the invention are set forth inthe accompanying drawings and the description below. Other features,objects, and advantages of the invention are apparent from thedescription and drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1 is an assembled cross-sectional view of a valve less micro pumpelement.

FIGS. 1A and 1B are cross-sectional views (somewhat simplified) of themicro pump element of FIG. 1 showing membrane actuations.

FIG. 1C is a blown-up view of a portion of FIG. 1A.

FIGS. 1D and 1E are cross-sectional views of an alternativeconfiguration of a micro pump element having tapered sidewalls for pumpcompartments, and showing membrane actuations.

FIG. 1F is a blown-up view of a portion of FIG. 1D.

FIG. 2 is a cross-sectional view of an exemplary “valve less” micro pumpcomprised of plural valve less micro pump elements in a series cascadedconnection arrangement.

FIG. 2A is a cross-sectional view of an alternative configuration of a“valve less” micro pump.

FIG. 3 is a perspective partial view of a stack of module layers thatprovide a micro pump element.

FIG. 4 is an exploded view of an intermediate module layer on an endcapmodule layer.

FIG. 4A is a perspective view of a portion of FIG. 4.

FIG. 5 is an exploded view of an intermediate module layer.

FIGS. 6A and 6B are plots of waveforms of signals applied to electrodesshowing phases for a peristaltic pumping sequence using the valve lessmicro pump of FIG. 2.

FIGS. 7A to 7F are diagrams depicting series configured “valve less”micro pump of FIG. 2 operation according to the phases for theperistaltic pumping sequence.

FIG. 8 is a functional block diagram of exemplary circuitry for themicro pump.

FIGS. 9A-9C are views of a roll to roll implementation for constructingvalve less micro pump elements.

DETAILED DESCRIPTION

Referring now to FIG. 1, a micro pump stack element 10 includes a pumpbody 12 enclosing a single, compartmentalized pump chamber 14. The pumpbody 12 is defined by two fixed walls 12 a, 12 b and two fixed end walls12 c, 12 d opposite to each other and along a direction perpendicular tothe two walls 12 a, 12 b. There are also two opposing walls (not shownin FIG. 1, which are orthogonal to fixed walls 12 a, 12 b and fixed endwalls 12 c, 12 d, all of which together form a cube-like structure.)

The pumping direction is shown by arrow 15. However, as explained below,the pump direction is dynamically reversible. That is, as will bediscussed below the designation of ports as inlets or outlets is withrespect to drive sequences. The walls 12 a, 12 b, 12 c and 12 d, and thetwo walls (not shown) of the pump body define the single chamber 14. Thesingle chamber 14 is compartmentalized by membranes 18 a-18 f that areanchored or affixed to two opposing walls, e.g., the two walls 12 c, 12d (also referred to herein as endcaps 12 c, 12 d). The membranes 18 a-18f are disposed to extend from the wall 12 a to the wall 12 b and the twowalls that are not shown in this view. The membranes 18 a-18 f separatethe pump chamber 14 into seven compartments 21 a-21 g. (In animplementation, the walls 12 a, 12 b, 12 c and 12 d of the pump body areprovided by stacking of micro pump modules as will be discussed below.)

In this implementation, each compartment 21 a-21 g includes a pair ofports 22, 24. For discussion purposes, an inlet is generally designatedas 22 and an outlet is generally designated as 24. These ports 22, 24are illustrated in phantom in FIG. 1, as the ports are not visible inthe cross-sectional view of FIG. 1. These ports 22, 24 are passagesthrough the walls 12 a, 12 b, and more particularly an absence ofportions of the walls 12 a, 12 b, respectively. The ports 22, 24 can beeither input ports or output ports according to a pump drive sequencethat is used. Throughout this discussion inlets or inputs are referredto by the number 22 and outlets or outputs are referred to by the number24.

For example, the compartment 21 a includes inlet 22 in the wall 12 a andoutlet 24 in the wall 12 b, with the compartment 21 a being defined by aportion of the wall 12 a, the wall (or endcap) 12 c, a portion of thewall 12 b, the two walls (not shown in FIG. 1), and the membrane 18 a.Other inlets and outlets are also labeled 22 and 24 respectively andother ones of the compartments 21 b-21 g are defined similarly.

The compartment 21 g (like compartment 21 a) at the opposite end of thepump chamber 14 is defined by the fixed wall (or endcap) 12 d of thepump body 12, the two walls (not shown), and the corresponding membrane18 f All intermediate compartments 21 b-21 f between the compartments 21a, 21 g have walls formed by two membranes and corresponding portions ofthe walls 12 a and 12 b and the two walls (not shown). In someembodiments of the micro pump stack element 10, there is at least oneintermediate compartment defined by portions of walls 12 a, 12 b and twomembranes. Although six membranes (and five intermediate compartments)are shown in the figures, the pump chamber can be extended or reducedwith additional or fewer intermediate compartments. The compartments 21a-21 g are fluidically isolated from each other.

An electrode (not explicitly shown in FIG. 1 to FIG. 1F, but which willbe discussed in FIGS. 2, 2A, and FIGS. 3-5) is attached to one side ofeach of the membranes 18 a-18 g and optionally to the end walls 12 c, 12d. The electrodes are connected to a drive circuit (see FIG. 8) thatdelivers voltages to the electrodes to activate the respectivemembranes, e.g., causing flexing of the membranes, through electrostaticattraction/repulsion.

Without activation, the membranes rest at nominal positions as shown inFIG. 1. Each membrane at rest can be substantially parallel to the endwalls 12 c, 12 d and the compartments 21 b-21 f can have the samenominal volume V_(i). In some implementations, the compartments 21 a and21 g each have the same nominal volume V_(j), which is about half of thenominal volume V_(i). For example, the distance between two adjacentmembranes in their nominal positions is about 50 microns, and thenominal volume V_(i) can range from nanoliters to microliters tomilliliters, e.g., 0.1 microliters.

In the implementations, where the compartments 21 a, 21 g each have thenominal volume V_(j) that is half the nominal volume of the intermediatecompartments 21 b-21 f, the distance between the membrane 18 a, 18 g intheir nominal positions and the end walls 12 c or 12 d is about 25microns. The nominal volume V_(i) can range from nanoliters tomicroliters to milliliters, e.g., 0.05 microliters. The compartments canalso have different dimensions. The dimensions are chosen based on,e.g., specific process requirements, as well as, power consumption,application considerations and so forth.

For example, the compartments 21 a, 21 b having a width of 25 micronscan allow a start-up function with a reduced peak drive voltage. Drivevoltages are discussed further below. As an example, the micro pumpelement 10 can have an internal volume having a length of about 1.5 mm,a width of about 1.5 mm, a total height (the cumulative height ofdifferent compartments) of 0.05 mm, and a total volume of about 0.1125μl.

One application of the micro pump element 10 is as a basic unit to builda series connected micro pump of which a peristaltic micro pump is aspecific example, all of which is discussed in FIG. 2 (below).

FIGS. 1A and 1B show two operational states of the micro pump stackelement 10. When actuated, each membrane of the pump chamber flexes inone of two opposite directions about a central, nominal location atwhich the membrane is at a rest state when it is not actuated, accordingto polarities of voltages provided to electrodes (not shown) onmembranes and endcaps. The rest positions of the membranes are shown inphantom dotted lines in each of FIGS. 1A and 1B.

Voltages are applied to the membranes 18 a-18 f according to a sequence.In response to a one portion of such as sequence, a compartment, e.g.,compartment 21 a, is compressed when the adjacent membrane 18 a definingthat compartment moves towards the endcap 12 c (see FIG. 1A) carrying anelectrode (not shown), reducing the volume of the compartment 21 a andisolating the compartment 21 a via a seal 28 (where the membrane 18 acontacts the endcap 12 c) to discharge a fluid, e.g., a gas or a liquidfrom the compartment 21 a. The membrane 18 a and endcap 12 c form a sealthat isolates one of the ports (generally 22 shown in phantom) from theopposite ports (generally 24 shown in phantom), as shown in FIG. 1C.Simultaneous to the compression of that compartment, e.g., 21 a, theimmediately adjacent compartment, e.g., compartment 21 b, is chargedwhen its two membranes 18 a and 18 b move away from each other to expandthe compartment 21 b volume (see FIG. 1A) that removes a seal that hadisolated, e.g., port 22 (shown in phantom) from the port 24 (shown inphantom), in a previous sequence of application of the voltages.

FIG. 1B shows a second operational state of the membranes when voltagepolarities are changed. Ports are not illustrated. The membranes areillustrated but not referenced.

As shown in FIGS. 1, 1A-1B the walls of the pump body are perpendicularto the nominal resting positions (see FIG. 1) of the membranes. However,if the walls of the pump body are perpendicular, there may exist smallvoid spaces 25 (e.g., FIG. 1A) between the walls of the pump body andmembranes, as shown in FIGS. 1A-1B. Within this void 25 could reside asmall amount of the fluid being pumped by the micro pump 10. This fluidwould remain each cycle as the fluid is pumped by the micro pump, andthus the presence of the voids 25 may represent a loss in pumpingefficiency.

Referring now to FIGS. 1D-1E, in order to alleviate the potential losscaused by voids 25, the walls of the pump body could be configured togradually taper (either a straight line taper, as shown or a curved linetaper) having a generally equilateral triangular, solid shape into thechamber as shown in FIGS. 1D-1F to substantially fill the voids 25(e.g., eliminate the voids shown in FIGS. 1A-1). The walls of the pumpbody 12 can be of a shape 23, e.g., a wedge-shape, that will occupy anyspace that would remain after a membrane flexed in response toapplication of voltages. That is, upon application of voltage to theelectrodes, electrostatic attraction of membranes having oppositeelectrostatic charges will have the membranes initially touch in themiddle and subsequently cause the membranes to “zipper” together as theattraction force towards each other causes the membranes to further flexand fully seal against the tapered portions of the pump body walls andsurfaces of the membrane.

Referring now to FIG. 2, a series configuration micro pump 30 (seriesconfiguration 30) comprising a plurality of micro pump elements 10 a-10c will now be described. In the series configuration 30 three elements10 a-10 c are shown. However, a given series configuration requires atleast three but can comprise more than three elements. The micro pumpelements 10 a-10 c each have a pump body (not referenced, but seeFIG. 1) having a pump chamber (not referenced, but see FIG. 1) that iscompartmentalized into plural compartments (not referenced, but see FIG.1), with the plural compartments having inlet ports providingunobstructed fluid ingress into the compartments and outlet portsproviding unobstructed fluid egress from the compartments. A pluralityof membranes 18 a-18 f is disposed in the pump chamber, the membranes 18a-18 f are anchored between opposing walls (not referenced, but seeFIG. 1) of the pump body to provide the plural compartments. Themembranes support electrodes (generally 27) that are segmented by stage(see FIG. 2A) and disposed on a major surface of each of the membranes18 a-18 g (and optionally on the body, as shown). The plurality of micropump elements 10 a-10 c are arranged in the series configuration withoutlets of a first one of the plurality of micro pump elements 10 a-10 cbeing fluidly connected to inlets of an adjacent one of the plurality ofmicro pump elements 10 a-10 c.

The series configuration of plural micro pump elements 10 a-10 c (usingthe stack 10 of FIG. 1) provides a “valve-less” series configuration 30.A “valve-less” micro pump is defined as a micro pump comprised of threeor more micro pump units that have no physical valve elements for inletsand outlets. That is, a valve-less micro pump has a configuration thateffectively provides inlet and outlet isolation during pumping withoutindividual physical valve structure elements built into the micro pumpstack elements 10 a-10 c, e.g., at inlet and/or outlet ports and withoutindividual physical valve structure elements between adjacent micro pumpstack elements.

In the series configuration 30, each of the plural micro pump stacks 10a-10 c has pairs of ports. These ports operate as either inlets oroutlets or in some implementations can be i/o (inlet/outlet) ports thatcan change function (inlet or outlet) dynamically and pump accordingly.For discussion purposes inlet ports are referred to as 22 and outletports are referred to as 24. These ports 22, 24 are illustrated inphantom in FIG. 2, as the ports are not visible the view of FIG. 2.

The series configuration 30 of the micro pump elements 10 a-10 c showsthe inlet ports 22 and the outlet ports 24 on opposing walls of the pumpbody. This is generally desirable, but not necessarily a requirement.Also in the series configuration 30, the micro pump stacks 10 a and 10 coperate as either input stages or output stages or I/O (input/output)pump stages whose functions can be changed dynamically, and the micropump stack 10 b being the middle stack operates as an interior isolationpump stage. The inlet ports 22 of the input stage 10 a connect to asource of fluid and the outlet ports 24 of a last one of the micro pumpelements 10 a-10 c are configured to connect to a sink to storepressurized fluid from the micro pump.

For discussion purposes, inlets are generally 22 and outlets aregenerally 24 and stage 10 a is an input stage and 10 c is an outputstage. Thus, inlets 22 a of the micro pump stack 10 a are fluidlycoupled to a source of fluid, such as a liquid or gas, e.g., ambientair. Outlets 24 a of the micro pump stack 10 a are fluidly coupled toinlets 22 b of the micro pump stack 10 b. Outlets 24 b of the micro pumpstack 10 b are fluidly coupled to inlets 22 c of the micro pump stack 10c and outlets 24 c of the micro pump stack 10 c are fluidly coupled to asink for fluid pumped through the pump. This sink can be pressurized airfrom the ambient that is blown out of the micro pump or stored forinstance in a tank (not shown).

Each of the micro pump stacks 10 a-10 c are driven using circuitrydiscussed below and driven according to phases such as those of FIGS. 6and 7A-7F.

Compared to a conventional pump used for similar purposes, the seriesconfiguration 30 and the micro pump elements 10 a-10 c use less materialthat is subject to less stress, and are driven using less power. Theseries configuration 30 has a size in the micron to millimeter scale,and can provide wide ranges of flow rates and pressure. Generally, theflow rate can be in the scale of microliters to milliliters. Anapproximate flow rate provided by a micro pump can be calculated as:

Flow Rate is given approximately by the total volume of the micropump×drive frequency×(l-loss factor).

Generally, the pressure is affected by how much energy, e.g., the drivevoltage, is put into the micro pump 30. In some implementations, thehigher the voltage, the larger the pressure. The upper limit on voltageis defined by break down limits of the series configuration 30 and thelower limit on the voltage is defined by a membrane's ability tosufficiently flex in response to the voltage. The pressure across aseries configuration 30 can be in the range of about micro psi to tenthsof a psi. A selected range of flow rate and pressure can be accomplishedby selection of pump materials, pump design, and pump manufacturingtechniques.

One described version of the series configuration 30 is a peristaltictype pump in the displacement type category. In one implementation,pumping occurs according to six phases, as set out in FIGS. 6 and 7A-7F,discussed below.

In operation, the membrane of a conventional pump (not including themicro pump discussed in the above incorporated by reference application)typically, the pump has a single pump chamber that is used in pumping.Gas is charged and discharged once during the charging and dischargingoperations of a pumping cycle, respectively. The gas outflows onlyduring half of the cycle, and the gas inflows during the other half ofthe cycle.

In the instant series configuration 30 each compartment is used inpumping. For example, two membranes between two fixed end walls formthree compartments for pumping. The micro pump can have a higherefficiency and can consume less energy than a conventional pumpperforming the same amount pumping, e.g., because the individualmembranes travel less distance and therefore are driven less. Theefficiency and energy saving scales as the number of membranes andcompartments between the two fixed end walls increases.

Generally, to perform pumping, each compartment includes a gas inlet anda gas outlet. The inlet and the outlet are valve-less, e.g., there areneither passive nor active valves that open or close in response topressure applied to the valves, in contrast to the embodiments discussedin the above incorporated by reference application.

Referring now to FIG. 2A, in one alternative embodiment of a valve lessseries configuration micro pump 30′, the series configuration of FIG. 2can be effectively provided by a single one of the stack elements 10 ofFIG. 1 (elongated in this view). In this alternative configuration, themicro pump 30′ is again “valve-less” and is produced from a single pumpbody 12 having two fixed walls 12 a, 12 b and two fixed end walls 12 c,12 d opposite to each other and along a direction perpendicular to thetwo walls 12 a, 12 b together with two opposing walls (not shown in FIG.2A, which are orthogonal to fixed walls 12 a, 12 b and fixed end walls12 c, 12 d, all of which together form a cube-like structure) withintermediate walls 13 a, 13 b to provide tympanic support for membranes(not referenced).

In this alternative series configuration 30′, the micro stack generally10 effectively has three stages of a general stack 10 and has pairs ofports generally 22 and 24. The effective three stages of the generalstack 10 is provided by a specific patterned electrode element 27 on themembranes and end caps (not referenced, but see FIG. 2). The ports canoperate as either inlets or outlets or in some implementations can bei/o (inlet/outlet) ports that can change function dynamically.Electrodes (generally 27) are shown on the membranes (not referenced) aswell as end electrodes on outer surfaces of the body. Alternatively,these electrodes could be within the body, provided that an insulatinglayer is used over any one of the end electrodes that could come incontact with an intermediate one of those electrodes.

Also in this series configuration 30′ the specific patterned electrodeelement 27 comprises three, spaced and electrically isolated electroderegions 27 a, 27 b, 27 c. These electrode regions are activatedaccording to the same phases and signals discussed below. Presuming thatthe micro pump stack 10 has a suitable aspect ratio of width ofelectrode regions to height of compartments that is sufficiently low toenable the membrane to flex in three regions, similar to the arrangementof FIG. 2, the electrode regions 27 a and 27 c can operate the stack 10to provide the input stages or output stages or I/O (input/output)stages, and the electrode region 27 b can operate the stack 10 as thepump stage.

In the implementation of FIG. 2 (and FIG. 2A), the absence of mechanicalvalve devices requires another mechanism to maintain a differentialpressure created by flow of gas in or out of a pump compartment. In thisimplementation of the micro pump element 10 actual mechanical valveselements are eliminated as the input/output stages are used forisolation (i.e. a valve function) in the series configuration ofmultiple micro pump element stages 10 a-10 c. Because no valves arerequired, the absence of such valves can reduce complications of pumpfabrication and cost. In addition, unlike the embodiments discussed inthe above incorporated by reference applications the mechanism discussedherein to maintain differential pressure created by flow of gas in orout of a pump compartment also obviates the need for nozzles anddiffusers as mentioned in the incorporated by reference application asan alternative “valve-less” implementation that would use nozzles anddiffusers. This mechanism is provided by the arrangement of FIG. 2 inwhich micro pump elements 10 a and 10 c provide ports (interchangeablyinput/output ports) and micro pump element 10 b is the actual pumpelement.

The membranes are driven to move (flex) by electrostatic force. Anelectrode is attached to each of the fixed end walls and the membranes.During the charging operation of a compartment, two adjacent electrodesof the compartment have the same positive or negative voltages, causingthe two electrodes and therefore, the two membranes to repel each other.During the discharging operation of a compartment, two adjacentelectrodes of the compartment have opposite positive or negativevoltages, causing the two electrodes and therefore, the two membranes toattract to each other. This is evident in FIGS. 1A and 1B. In thisimplementation of the micro pump it is desired to drive the membranessuch that flexure of the membranes cause each set of membranes thatconstrict a compartment to seal that compartment, as denoted byreference 28 in FIG. 1C and reference 29 in FIG. 1F.

The two electrodes of a compartment form a parallel plate electrostaticactuator. The electrodes generally have small sizes and low static powerconsumption. A high voltage can be applied to each electrode to actuatethe compartment while the actuation is performed at a relatively lowcurrent.

As described previously, each membrane of the micro pump moves in twoopposite directions relative to its central, nominal position.Accordingly, compared to a compartment in a conventional pump, to expandor reduce a compartment by the same amount of volume, the membrane ofthis specification travels a distance less than, e.g., half of, themembrane in the conventional pump. As a result, the membrane experiencesless flexing and less stress, leading to longer life and allowing forgreater choice of materials. The starting drive voltage for theelectrode on the membrane needs be sufficient to drive the membranessuch that each travels at least half of the distance or over half thedistance, which would slightly flatten the membranes where a pair ofdriven membranes touched. For a compartment having two membranes, sinceboth membranes are moving, the time it takes to reach the pull-involtage can be shorter.

Microelectromechanical systems such as micro pumps having the abovedescribed features are fabricated using roll to roll (R2R) processing.Roll-to-roll processing is becoming employed in manufacture ofelectronic devices using a roll of flexible plastic or metal foil as abase or substrate layer. Roll to roll processing has been used in otherfields for applying coatings and printing on to a flexible materialdelivered from a roll and thereafter re-reeling the flexible materialafter processing onto an output roll. After the material has been takenup on the output roll or take-up roll the material with coating,laminates or print materials are diced or cut into finished sizes.

Below are some example criteria for choosing the materials of thedifferent parts of the micro pump.

Pump body—The material used for the body of a pump needs to be strong orstiff enough to hold its shape to provide the pump chamber volume. Insome implementations, the material is etch-able or photo-sensitive sothat its features can be defined, machined and/or developed. Sometimesit is also desirable that the material interact well, e.g., adheres withthe other materials in the micro pump. Furthermore, the material iselectrically non-conductive. Examples of suitable materials include SU8(negative epoxy resist), and PMMA (Polymethyl methacrylate) resist,Polyvinylidene fluoride (PVDF), Polyethylene terephthalate (PET),Polytetrafluoroethylene (PTFE) such as Teflon® The Chemours Company.

Membrane—The material for this part forms a tympanic structure (a thintense membrane covering the pump chamber) that is used to charge anddischarge the pump chamber. As such, the material is required to bend orstretch back and forth over a desired distance and has elasticcharacteristics. The membrane material is impermeable to fluids,including gas and liquids, is electrically non-conductive, and possessesa high breakdown voltage. Examples of suitable materials include siliconnitride and Polyvinylidene fluoride (PVDF), Polyethylene terephthalate(PET), Polytetrafluoroethylene (PTFE) such as Teflon® The ChemoursCompany.

Electrodes—These structures are very thin and comprised of material thatis electrically conductive. Because the electrodes do not conduct muchcurrent, the material can have a high electrical sheet resistance,although the high sheet resistance feature is not necessarily desirable.The electrodes are subject to bending and stretching with the membranes,and therefore, it is desirable that the material is supple to handle thebending and stretching without fatigue and failure. In addition, theelectrode material and the membrane material will need to adhere well toeach other, e.g., will not delaminate from each other, under theconditions of operation. Examples of suitable materials includealuminum, gold, and platinum.

Electrical interconnects—The drive voltage is conducted to the electrodeon each membrane of each compartment. Electrically conducting paths tothese electrodes can be built using conductive materials, e.g.,aluminum, gold, and platinum.

Referring now to FIGS. 3-5, a modularized “valve-less” seriesconfiguration 30 comprised of a series configuration (not shown in thesefigures) of micro pump elements is shown.

Referring to FIG. 3, module layers 42 can be series connected (notshown) and stacked (as shown) to provide a stack of the compartments(not referenced) for a given micro pump element to provide a modularizedmicro pump element 10′. The modularized micro pump element 10′ iscomprised of many module layers 42 (FIG. 3) that form intermediatecompartments of the micro pump element 10′ and plural micro pumpelements 10′ can be series connected as well as end compartments toprovide a modularized micro pump stack (not shown in FIG. 3). Themodularized micro pump element 10′ is similar to that described in theabove mentioned incorporated by reference published application, exceptthat the present modularized micro pump element 10′ eliminates the valvedevices used with the micro pump stack in the above mentionedincorporated by reference published application. The modularized micropump element 10′ arranged in a series configuration of micro pump stackelements 10′, similar to that discussed above for elements 10.

Specific details on modularized micro pump fabrication using siliconbased lithographic as well as roll to roll processing are discussedbelow.

Referring now to FIG. 4, a pump end cap 44 forming a fixed pump wall(similar to walls 12 c, 12 d FIGS. 1A, 1B). An electrode 48 is attachedto the pump end cap 44 for activating a compartment 49. A single modulelayer 42 forms a portion of a pump body 50 between the pump end cap 44with the electrode 48, and a membrane 52 along with an electrode 54 thatis attached to the membrane 52 on the opposite side of the pump body 50(similar as the membranes in FIGS. 1A, 1B). The electrode 54 includes alead 55 to be connected to a drive circuit external to the module layer42. FIG. 4A shows tapered walls of an alternative for the pump body 50.

The membrane 52, the pump end cap 44, and the pump body 50 can have thesame dimensions, and the electrodes 48, 54 can have smaller dimensionsthan the membrane 52 and the other elements. In some implementations,the membrane 52 has a dimension in a range of about a hundred microns tomillimeters up to about several centimeters for thicknesses of about 5microns. For thinner membranes, the dimensions can be smaller. The limiton the low end of the thickness range is up to where there is nopermanent deformation of the membrane. For the higher end of thethickness range the limit is where membrane remains tympanic. The pumpbody 50 would have corresponding dimensions. The thickness of the pumpbody defines the nominal size of the compartment 49 (similar tocompartments FIG. 1A). The electrodes 48, 54 have dimensions thatsubstantially correspond to inner dimensions of the pump body 50. Insome implementations, the electrodes 48, 54 have a surface area of about2.25 mm² and a thickness of about 0.15 microns. Although the electrodesare shown as a pre-prepared sheet to be attached to the other elements,the electrodes can be formed directly onto those elements, e.g., byprinting. The different elements of the module layers can be bonded toeach other using an adhesive. In some implementations, a solvent can beused to partially melt the different elements and adhere them togetheror laser welding or ultrasonic welding can also be used.

Referring to FIG. 5, intermediate compartments are formed using a modulelayer 42. The module layer 42 includes a pump body 50, an electrode 54,and a membrane 52 formed between the electrode 54 and the pump body 50.The assembled module layers have unobstructed apertures that provideinlets and outlets and provided unobstructed paths through the pump body50 and the compartment. A pressure differential is established with theconfiguration discussed above in FIG. 2. Multiple, e.g., two, three, orany desired number of, module layers of FIG. 5 are stacked on top ofeach other to form multiple intermediate compartments in a pump chamber.In the stack 40, each membrane is separated by a pump body and each pumpbody is separated by a membrane. To form a complete pump (such as amicro pump element 10), a module layer of FIG. 4 (end cap module) isplaced on each of the top and bottom ends of the stack so that the pumpend caps of the module layer form two fixed end walls of the pumpchamber.

A charging operation is established when pressure external to a modulelayer is larger than pressure inside the module layer, and thus a fluidflows from outside the module layer into the compartment. When theinternal pressure is higher than the external pressure, a dischargeoperation is established and fluid flows from the compartment away tothe outside of the module layer. Discharge occurs by displacementmeaning that the pump can discharge fluid at ambient pressure. Duringthe discharge operation, the fluid in the compartment does not flow outfrom the inlet due to the configuration, as driven as discussed below.Effectively, during the charging operation, the outlet is closed so thatthe fluid does not flow out of the compartment, and during thedischarging operation, the outlet is open and the fluid flows out of thecompartment.

Referring now to FIGS. 6A, 6B, timing waveforms for a peristalticsequence are shown. As shown there are six phases to form a sequencethat repeats. FIG. 6A shows a true phase and FIG. 6B shows thecomplement of the true phase, which together provide for six signals S1,S1′ S2, S2′ and S3, S3′ to drive respective groups of membranes, as morefully explained in FIGS. 7A-7F. The timing waveforms represent when astage is open (logic 0) and when a stage is closed (logic 1). A clocksignal is also shown.

Referring now to FIGS. 7A-7F, states of each of the compartments in eachof the stages in the series configuration 30 are shown. I/O ports whilepresent, are not shown in these figures. In each figure the peristalticsequence is shown and is labeled according to a phase, and a table isshown with the phases each of the channels 1-7 (i.e., paths between aninput and an output of each module layer) is in. Thus for FIG. 7A,Channel 1 has stage 10 a open (logic 0), stage 10 b closed (logic 1) andstage 10 c closed (logic 1), which corresponds to phase 1, whereas,Channel 2 has stage 10 a closed (logic 1), stage 10 b open (logic 0) andstage 10 c open (logic 0), which corresponds to phase 4. The operationof opening and closing channels is provided by applying drive signals toeach of the electrodes, as shown.

The micro pump stacks 10 a-10 c are driven according to the phasesdenoted in the peristaltic sequence. Other sequences may be possible. Inthe peristaltic sequence, as shown in FIG. 7A, for Channel 1 stack 10 ais in an intake phase, i.e., has its inlet unobstructed (as are Channels3, 5 and 7) but its outlet is obstructed by the adjacent stack 10 b.This allows Channel 1 in stack 10 a to fill with fluid by having thefirst stack driven by the appropriate phase of the waveforms of e.g.,FIG. 6, but having the adjacent stack being driven by a waveform of anopposite polarity to those waveforms that are driving the first stack.The opposite occurs for Channels 2, 4 and 6, as shown.

The first stack 10 a inputs air into channels 1, 3, 5, and 7(compartments 18 a, 18 c, 18 e and 18 g FIG. 1) during an intake phaseof those channels in stack 10 a. However, the second stack 10 b andthird stack 10 c each have its channels 1, 3, 5, and 7 (compartments 18a, 18 c, 18 e and 18 g FIG. 1) obstructed by the membranes, during theintake phase of stack 10 a, thus effectively providing functionality ofopening input valves at inputs of the first stack and closing outputvalves at outlets of the first stack 10 a for channels 1, 3, 5 and 7.

Simultaneously, the first stack 10 a closes off channels 2, 4, and 6(compartments 18 b, 18 d, and 18 f FIG. 1) during an output phase ofthose channels in stack 10 a. However, the second stack 10 b and thirdstack 10 c each have its channels 2, 4, and 6 (compartments 18 b, 18 d,and 18 f FIG. 1) unobstructed by the membranes, during the output phaseof those channels of stack 10 b and stack 10 c, thus effectivelyproviding functionality of closing input valves at inlets of the firststack 10 a and opening output valves at outlets of the second and thirdstacks 10 a for channels 2, 4, and 6.

Meanwhile, the second stack 10 b has its compartments 18 b, 18 d and 18f obstructed by the membranes in compartments 18 a, 18 c, 18 e and 18 gof the first stack 10 a and by the membranes in compartments 18 a, 18 c,18 e and 18 g of the third stack 10 c, thus effectively providingfunctionality of valves at inlets and outlets of the second stack 10 b.Any air that was in the compartments 18 a, 18 c, 18 e and 18 g of thefirst stack and the third stack is pumped into compartments 18 b, 18 dand 18 f of the second stack and in this example the output of the micropump 30.

For example, referring back to FIG. 7A, the voltage on the electrode onthe fixed wall is negative and the voltage applied to the electrode onthe first membrane adjacent to the wall is also negative to repel thatfirst membrane away from the wall. However, the voltage on the secondmembrane is positive, which would tend to have second membrane attractto the first membrane, etc. Thus, voltages of same signs are applied tothe electrodes on opposing walls of these other compartments. Thus,voltages of opposite signs cause the two opposing walls of thecompartments to attract each other and the voltages of the same signscause the two opposing walls of the compartments to repel each other.The polarities for each of the signals applied to the electrodes willthus be according to the drive sequence. The membranes move towards adirection of the attraction force or a direction of the repelling force.As a result, each sequence of a pumping cycle (six sequences for theperistaltic sequence), some of the compartments discharge and othercompartments simultaneously charge, and in other sequences of thepumping cycle, others of the compartments discharge and simultaneouslycharge as per FIGS. 7A-7F.

The material of the membranes and the voltages to be applied to themembranes and the end walls are chosen such that when activated, eachmembrane expands at least half the distance d between the nominalpositions of adjacent membranes and in some implementations the membranecan be driven to expand an additional amount more than half of thedistance (thus distorting the membranes somewhat). In the endcompartments where the distance between the nominal position of themembrane and the fixed wall is d 2, the activated membrane reduces thevolume of the compartment to close to zero (in a discharging operation)and expands the volume of the compartment to close to 2*V_(e). For theintermediate compartments, by moving each membrane by d/2, a volume of acompartment is expanded to close to 2*V_(i) in a charging operation andreduced to close to zero in a discharging operation. The micro pump canoperate at a high efficiency.

The period of the pumping cycle can be determined based on the frequencyof the drive voltage signals. In some implementations, the frequency ofthe drive voltage signal is about Hz to about KHz, e.g., about 2 KHz. Aflow rate or pressure generated by the pumping of the micro pump can beaffected by the volume of each compartment, the amount of displacementthe membranes make upon activation, and the pumping cycle period.Various flow rates, including high flow rates, e.g., in the order ofml/s, and pressure, including high pressure, e.g., in the order oftenths of one psi, can be achieved by selecting the differentparameters, e.g., the magnitude of the drive voltage. As an example, amicro pump can include a total of 15 module layers.

The sets of electrical signals are applied to the micro pump elementssuch that a first set of the electrical signals cause in a first one ofthe plurality of micro pump elements, a first one of the pluralcompartments to compress and at least one adjacent one of the pluralcompartments to expand substantially simultaneously and a second set ofthe electrical signals applied simultaneously with the first set tocause in a second, adjacent one of the plurality of micro pump elementsa first one of the plural compartments to expand and at least oneadjacent one of the plural compartments to compress substantiallysimultaneously. Other sets of electrical signals cause correspondingactions, especially according to a peristaltic sequence having sixphases, which for a micro pump where the plurality of micro pumpelements consist essentially of an input element, a pump element and anoutput element, according to:

-   -   011    -   001    -   101    -   100    -   110    -   010        with 0 corresponding to a first one of open or close of a        compartment, 1 corresponding to a second, different one of open        or close of a compartment and each of the phases having the        values for respectively the input element, the pump element and        the output element.

Drive Circuitry

A drive circuit for applying voltages to the electrodes takes a low DCvoltage supply and converts it to a pulse level waveform. The frequencyand shape of the waveform can be controlled by a voltage controlledoscillator. The drive voltage can be stepped up by a multiplier circuitto the required level. To operate compartments of the pump in theirdischarging state, voltages of opposite polarities are applied to theelectrodes on opposing walls and membranes of these compartments to makethe membranes flex according to the sequence. These signals applied tothe electrodes are thus the true and complement versions of thewaveforms of FIG. 6.

Referring now to FIG. 8, an example of drive circuitry 500 for applyingvoltages is shown. The drive circuitry 500 receives a supply voltage502, a capacitance voltage current 504 signal, and pump control 516, andoutputs drive voltages 506 to electrodes of the micro pump 30. In someimplementations, the supply voltage 502 is provided from a system inwhich the micro pump 100 is used. The supply voltage can also beprovided by an isolation circuit (not shown). Power can be provided by abattery or other sources. The drive circuitry 500 includes a highvoltage multiplier circuit 508, a voltage controlled oscillator (“VCO”)510, a waveform generator circuit 512, and a feedback and controlcircuit 514. The high voltage multiplier circuit 508 multiplies thesupply voltage 502 up to a desired high voltage value, e.g., about 100Vto 700V, nominally, 500 V. Other voltages depending on materialcharacteristics, such as dielectric constants, thicknesses, mechanicalmodulus characteristics, electrode spacing, etc. can be used. In someimplementations, the high voltage multiplier circuit 508 includes avoltage step-up circuit (not shown). The voltage controlled oscillator510 produces a drive frequency for the micro pumps. The oscillator 510is voltage controlled and the frequency can be changed by an externalpump control signal 516 so that the pump 100 pushes more or less fluidbased on flow rate requirements. The waveform generator circuit 512generates the drive voltages for the electrodes. As describedpreviously, some of the drive voltages are AC voltages with a specificphase relationship to each other. The waveform generator circuit 512controls these phases as well as the shape of the waveforms. Thefeedback and control circuit 514 receives signals that provide measuresof capacitance, voltage and or current in the micro pump and the circuit514 can produce a feedback signal to provide additional control of thewaveform generator 512 of the circuit 500 to help adjust the drivevoltages for desired performance.

Integration of the Systems in Devices

The micro pump systems described above can be integrated in differentproducts or devices to perform different functions. For example, themicro pump systems can replace a fan or a blower in a device, e.g., acomputer or a refrigerator, as air movers to move air. Compared to theconventional fans or blowers, the micro pumps may be able to performbetter at a lower cost with a higher reliability. In someimplementations, these air movers are directly built into a host at afundamental level in a massively parallel configuration. In general, theseries configuration 30 can be used in many applications that call forperistaltic pumps.

In some implementations, the micro pump systems receive power from ahost product into which the systems are integrated. The power can bereceived in the form of a single, relatively low voltage, e.g., as lowas 5V or lower, to a drive circuitry of the micro pump systems, e.g.,the drive circuitry 500 of FIG. 11.

System Configuration

The module layer stack can be viewed as module layers connected inparallel. The volume of each individual module layer, V_(i) or V_(e), issmall. In some implementations, even the total volume of all layers inthe stack is relatively small. In some implementations, multiple stacksor micro pumps can be connected in parallel to increase the total volumeflow rate.

Similarly, the pressure capability of an individual micro pump isrelatively low. Even though there are multiple module layers in a stack,the layers do not increase the total pressure of the stack because theyare connected in parallel. However, the pressure of the stack can beincreased when multiple stacks or micro pumps are connected in series.

In some implementations, the micro pumps 30 are connected in series aredriven at different speeds to compensate for different mass flow rates.For example, built-in plenums or plumbing in a tree type configurationcan also be used to compensate for different mass flow rates.Effectively, the serially connected stacks in each row can provide atotal pressure substantially equal the sum of the individual stackpressures.

Alternative Operation Modes

An alternative mode of operation of the series connected set ofvalve-less micro pump elements is dynamic mode change. With thesevalve-less micro pump elements connected in a series configuration thisneed not be a fixed correspondence between inlet and outlet functions.Thus by driving the micro pump elements according to a first peristalticsequence in a first mode of operation, a first one of the plurality ofmicro pump elements having a port that is an inlet port of the seriesconfiguration, and a last one of the plurality of micro pump elementshaving a port that is an outlet port of the series configuration.However, by driving the micro pump elements according to a second,different peristaltic sequence for a second, different mode ofoperation, with the port of the first one of the plurality of micro pumpbeing the outlet port of the series configuration, and the port of thelast one of the plurality of micro pump elements being the inlet port ofthe series configuration the second mode dynamically changes the portsthat function as the input port and output port of the seriesconfiguration. Properly therefore these are referred to as I/O ports.

In this mode the first and second peristaltic sequences each have sixphases, with the first peristaltic sequence given as:

-   -   011    -   001    -   101    -   100    -   110    -   010        and the second, different peristaltic sequence given as:    -   100    -   112    -   010    -   011    -   001    -   101        with “0” being a logic value corresponding to a first one of        open or close of a compartment, “1” being a logic value        corresponding to a second, different one of open or close of a        compartment and each of the phases having the values for        respectively the input element, the pump element and the output        element.

Alternative Construction/Operation Modes

A novel construction of a series connected set of valve-less micro pumpelements is can have built in redundancy that together with dynamic modechanges can provide various novel operation modes. With these valve-lessmicro pump elements connected in a series configuration the seriesconnection can have a variable number of or arrangement of units devotedto inlet, pump, and outlet functions. Such a micro pump would haveseveral (more than three), e. g., four, ten or 15, or more or many moremicro pump elements each having a pump chamber compartmentalized intoplural compartments, with compartments of the plural compartments havinginlet ports providing unobstructed fluid ingress into the compartmentsand outlet ports providing unobstructed fluid egress from thecompartments, together with membranes disposed anchored between opposingwalls of the pump body and forming the plural compartments andelectrodes disposed on major surfaces of the membranes.

Drive circuitry provide signals to the plurality of electrodes accordingto a sequence, with a first portion of the plurality of micro pumpelements driven by a first subset of signals in the sequence, a secondportion of the plurality of micro pump elements driven by a secondsubset of signals in the sequence, and with a third portion of theplurality of micro pump elements driven by a third subset of signals inthe sequence. The first portion of micro pump elements provides an inputelement, the second portion of the plurality of micro pump elementsprovides a pump element and the third portion of the plurality of micropump elements provides an output element of the series configuration.These micro pump elements are dynamically configurable, meaning that thefunctions of the first and third portions are dynamically configurableby adjusting the sequence. The first, second and third subsets ofsignals are applied as a peristaltic sequence, with each of the first,second and third subsets of the peristaltic sequence having six phases,with an exemplary peristaltic sequence being

-   -   011    -   001    -   101    -   100    -   110    -   010        with “0” being a logic value corresponding to a first one of        open or close of a compartment, “1” being a logic value        corresponding to a second, different one of open or close of a        compartment and each of the phases having the values for        respectively the input element, the pump element and the output        element. Typically, the drive circuitry would be responsive to a        control signal to change the sequence. The control signal would        typically be generated external to the micro pump and the drive        circuitry by an external system, device and/or circuit (FIG. 8).

Exemplary Applications

Exemplary applications of the series configuration 30 can be those asdiscussed in the above mentioned incorporated by reference publications,without substantial variation, presuming use of the seriesinterconnected micro pump modules in a valve-less configuration.Similarly, construction of the series interconnected micro pump modulesin a “valve-less” configuration is without substantial variation to thetechniques described in the above incorporated by reference publicationsbut for modifications of masks or elimination processing that was neededfor formation of inlet and outlet valves on the micro pump modules andsubsequent fabrication of the micro pumps using the seriesconfiguration.

Fabrication techniques can include the Roll to Roll processing asdescribed below or as described in the above incorporated by referencepublications.

Roll to Roll Processing for Producing Micro Pumps

A roll to roll processing line comprises several stations that can be orinclude enclosed chambers at which deposition, patterning, and otherprocessing occurs. Processing viewed at a high level thus can beadditive (adding material exactly where wanted) or subtractive (removingmaterial in places where not wanted) or combinations of both. Depositionprocessing includes evaporation, sputtering, and/or chemical vapordeposition (CVD), as needed, as well as printing. The patterningprocessing can include depending on requirements techniques such asscanning laser and electron beam pattern generation, machining, opticallithography, gravure and flexographic (offset) printing depending onresolution of features being patterned. Ink jet printing and screenprinting can be used to put down functional materials such asconductors. Other techniques such as imprinting and embossing can beused.

The original raw material roll is of a web of flexible material. In rollto roll processing the web of flexible material can be any such materialand is typically glass or a plastic or a stainless steel. While any ofthese materials (or others) could be used, plastic has the advantage oflower cost considerations over glass and stainless steel and is abiocompatible material for production of the micro pump when used in aCPAP type (continuous positive airway pressure) breathing device (seeincorporated by reference applications). In other applications. of themicro-pump, e.g., as a cooling component for electronic components othermaterials such as stainless steel or other materials that can withstandencountered temperatures would be used, such as Teflon and otherplastics that can withstand encountered temperatures.

The membrane material is required to bend or stretch back and forth overa desired distance and thus should have elastic characteristics. Themembrane material is impermeable to fluids, including gas and liquids,is electrically non-conductive, and possesses a high breakdown voltage.Examples of suitable materials include silicon nitride and Teflon. Thematerial of the electrodes is electrically conductive. The electrodes donot conduct significant current. The material can have a high electricalresistance, although the high resistance feature is not necessarilydesirable. The electrodes are subject to bending and stretching with themembranes, and therefore, it is desirable that the material is supple tohandle the bending and stretching without fatigue and failure. Inaddition, the electrode material and the membrane material adhere well,e.g., do not delaminate from each other, under the conditions ofoperation. Examples of suitable materials include, e.g., aluminum, gold,silver, and platinum layers (or conductive inks such as silver inks andthe like).

Referring to FIGS. 9A-9C, a roll to roll processing approach to providethe modularized micro pump is shown. The micro pump has features thatare moveable in operation. i.e., the membrane (which flexes) andunobstructed passages into and out of chambers of the micro pumpelements to provide valve functions when configured as discussed above.The micro pump is fabricated using roll to roll processing where a rawsheet (or multiple raw sheets) of material is passed through pluralstations to have features applied to the sheet (or sheets) and the sheet(or sheets) are subsequently taken up to form parts of the repeatablecomposite layers to ultimately produce a composite sheet of fabricatedmicro-pumps.

Referring to FIG. 9A, a sheet 304 of a flexible material such as a glassor a plastic or a stainless steel is used as a web, e.g., the materialis a plastic sheet, e.g., polyethylene terephthalate (PET). The sheet304 is a 50 micron thick sheet of PET. Other thicknesses could be used(e.g., the sheet 304 could have a thickness between, e.g., 25 micronsand 250 microns. The thicknesses are predicated on desired properties ofthe microelectromechanical system to be constructed and the handlingcapabilities of roll to roll processing lines. These considerations willprovide a practical limitation on the maximum thickness. Similarly, theminimum thicknesses are predicated on the desired properties of themicroelectromechanical system to be constructed and the ability tohandle very thin sheets in roll to roll processing lines.

For the example where the microelectromechanical system is the micropump, the layers would have thicknesses as mentioned above approximately50 microns for the pump body. However, other thicknesses are possibleeven for the micro pump. The sheet 304 from a roll (not shown) ispatterned at an ablation station, e.g., a laser ablation station. A mask(not shown), (or a direct write process not shown), is used to configurethe laser ablation station to remove material to define or form thecompartments of the micro pump, as well as alignment holes (not shownbut will be discussed below). Vias are also provided for electricalconnections, as shown. The micro-machining ablates away the plastic toform the compartment of the micro pump while leaving the frame portionof the pump body and also forms the unobstructed passages for inlets andoutlets.

Referring now to FIG. 9B, the sheet 304 with the defined features of thecompartment and unobstructed passages is laminated at a laminationstation to a second sheet 308, e.g., 5 micron thick sheet of PET, with ametallic layer 310 of Al of 100 A on a top surface of the sheet. Thissecond sheet 308 forms the membranes over the pump bodies provided bythe defined features of the compartment regions. The second sheet isalso machined to provide the alignment holes (not shown) prior to orsubsequent to coating of the metallic layer.

Prior to lamination of the second sheet 308 to the first sheet 304, thesecond sheet 308 is also provided with several dispersed holes (notshown) over some areas that will expose the pump bodies structures.These dispersed holes are used by a machine vision system to reveal andrecognize underlying features of the pump body units on the first sheet304. Data is generated by noting the recognized features in the firstsheet through the holes. These data will be used to align a thirdablation station when forming electrodes from the layer over the pumpbodies (discussed below). The second sheet 308 is laminated to and thussticks (or adheres) to the first sheet 304.

At this point, a composite sheet 310 of repeatable units of the micropump, e.g., pump body and movable and releasable features, withmembranes are formed, but without electrodes formed from the layer onthe membrane. The machine vision system produces a data file that isused by the laser ablation system in aligning a third laser ablationstation with a fourth mask (or direct write) such that a laser beam fromthe laser ablation system provides the electrodes 210 (FIG. 2B)according to the fourth mask, with the electrodes in registration withthe corresponding portions of the pump bodies. The electrodes are formedby ablating away the metal in regions that are not part of theelectrodes and conductors, leaving isolated electrodes and conductors onthe sheet. The registration of the patterned electrodes to the pump bodyis thus provided by using the machine vision system to observe featureson the front side (could also be the backside) of the laminatedstructure providing positioning data that the laser ablation system usesto align a laser beam with the fourth mask, using techniques commonlyfound in the industry.

Referring now to FIG. 9C, the composite sheet 310 is fed to a thirdlaser ablation station to form the electrodes by ablating the 100 A° Allayer deposited on the second sheet that formed the membrane. Thecomposite sheet 310 is patterned according to a fourth mask (or directwrite) to define the electrodes over corresponding regions of the pumpbody. The third ablation station ablates away metal from the secondlayer leaving isolated electrodes on the sheet.

A jig (not shown) that can comprise vertical four posts mounted to ahorizontal base is used to stack individual ones of cut units. On thejig an end cap (e.g., a 50 micron PET sheet with a metal layer) isprovided and over the end cap a first repeatable unit is provided. Therepeatable unit is spot welded (applying a localized heating source) (orlaminated) to hold the unit in place on the jig. As each repeatable unitis stacked over a previous repeatable unit that unit is spot welded. Thestack is provided by the inlets on one side and outlets one the opposingside. The passages can be staggered resulting from arrangement of thepassages so as to have a solid surface separating each of the passagesin the stack (See FIG. 3). Once a stack is completed, a top cap (notshown) can be provided. The stack unit is sent to a lamination stationnot shown, where the stack is laminated, laminating all of therepeatable units and caps together. The end cap and top cap can be partof the packaging as well. Otherwise, repeatable units can be laminatedone or a few layers of a time. An electrode is attached to the pump endcap for activating the compartment. The electrode includes a lead (notshown) to connect to a drive circuit (not shown). After lamination ofthe stack, the stack units are diced to form individual micro pumps.

Other stacking techniques for assembly are possible with or without thealignment jig, pin or holes.

Elements of different implementations described herein may be combinedto form other embodiments not specifically set forth above. Elements maybe left out of the structures described herein without adverselyaffecting their operation. Furthermore, various separate elements may becombined into one or more individual elements to perform the functionsdescribed herein. Other embodiments are within the scope of thefollowing claims. For example, a micro pump may include a micro pumpelement that includes a pump body having walls that enclose a pumpchamber, a plurality of inlet ports with unobstructed fluid ingress intothe pump chamber and a plurality of outlet ports with unobstructed fluidegress from the pump chamber, top and bottom caps on opposing portionsof the pump body, plural membranes that compartmentalized the pumpchamber to provide plural compartments in the pump chamber, with each ofthe plurality of membranes carrying on a major surface thereof threemutually electrically isolated electrode elements that cause themembrane to undulate according to different phases of signals appliedsuccessively to the mutually electrically isolated electrode elements.

What is claimed is:
 1. A micro pump comprising: a plurality of micropump elements, each micro pump element comprising: a pump body havingwalls that enclose a pump chamber that is compartmentalized into pluralcompartments, a plurality of inlet ports each with unobstructed fluidingress into corresponding ones of the plural compartments and aplurality of outlet ports each with unobstructed fluid egress fromcorresponding ones of the plural compartments; a plurality of membranesdisposed in the pump chamber, with the plurality of membranes affixed tothe walls of the pump body, and which compartmentalized the chamber toprovide the plural compartments; and a plurality of electrodes, with afirst pair of the plurality of electrodes disposed on a pair of opposingwalls of the pump body, and each of the remaining ones of the pluralityof electrodes disposed on a major surface of a corresponding one of theplurality of membranes; with the plurality of micro pump elementsarranged in a series connected configuration that has outlets of a firstone of the plurality of micro pump elements fluidly connected to inletsof an immediately adjacent one of the plurality of micro pump elements.2. The micro pump of claim 1 wherein the plurality of micro pumpelements includes an input element, a pump element and an outputelement.
 3. The micro pump of claim 1 wherein the plurality of micropump elements are modularized micro pump elements.
 4. The micro pump ofclaim 1 wherein each of the plurality of micro pump elements includes apair of end caps that together with the walls of the pump body formedthe chamber.
 5. The micro pump of claim 1 wherein the inlet ports andoutlet ports are on opposing walls of the pump body of each of the micropump elements.
 6. The micro pump of claim 1 wherein the inlet ports andthe outlet ports are on opposing walls of the pump body, the inlet portsof a first one of the micro pump elements configured to connect to asource of fluid and the outlet ports of a last one of the micro pumpelements are configured to connect to a sink to store pressurized fluidfrom the micro pump.
 7. The micro pump of claim 1 further comprising: adrive circuit to supply voltage signals to the plurality of electrodes,which voltage signals cause a first pair of adjacent membranes todeflect towards each other to obstruct fluid flow in a firstcorresponding compartment and a second pair of adjacent membranes todeflect away from each other to provide unobstructed fluid flow in asecond, different corresponding compartment.
 8. The micro pump of claim1 further comprising: voltage driver circuitry to produce voltagesignals that are fed to the plurality of electrodes; with a first set ofthe voltage signals to cause in a first one of the plurality of micropump elements, a first one of the plural compartments to compress and atleast one adjacent one of the plural compartments to expandsubstantially simultaneously; and with a second set of the voltagesignals applied substantially simultaneously with the first set to causein a second, adjacent one of the plurality of micro pump elements afirst one of the plural compartments to expand and at least one adjacentone of the plural compartments to compress substantially simultaneously.9. The micro pump of claim 1 further comprising: voltage drivercircuitry to produce voltage signals that are fed to the plurality ofelectrodes according to a sequence.
 10. The micro pump of claim 9wherein the sequence is a peristaltic sequence.
 11. The micro pump ofclaim 10 wherein the peristaltic sequence has six phases.
 12. The micropump of claim 11 wherein the six phases of the peristaltic sequence arefor the plurality of micro pump elements consisting essentially of aninput element, a pump element and an output element: 011 001 101 100 110010 with 0 corresponding to a first one of open or close of acompartment, 1 corresponding to a second, different one of open or closeof a compartment and each of the phases having the values forrespectively the input element, the pump element and the output element.13. The micro pump of claim 1 wherein the walls of the pump body haveinternal tapered edges within each of the respective compartments. 14.The micro pump of claim 13 wherein the tapered edges have a pair oftapers that are at a slope selected to make contact with correspondingone of the membranes when the membranes flex.
 15. The micro pump ofclaim 13 wherein the tapered edge portions have a substantiallyequilateral triangular, solid shape.
 16. The micro pump of claim 1consisting essentially of three micro pump elements connected togetherin a series configuration, where outlets of a first micro pump elementare fluidly connected to inlets of an adjacent, succeeding micro pumpelement.
 17. The micro pump of claim 1 wherein the micro pump is avalve-less micro pump.
 18. The micro pump of claim 1 further comprising:voltage driver circuitry to produce voltage signals that are fed to theplurality of electrodes according to a selectable pair of first andsecond peristaltic sequences, with each of the first and secondperistaltic sequences having six phases and each of the micro pumpelements has plural compartments and for the plurality of micro pumpelements consisting essentially of an input element, a pump element andan output element, respectively, the first peristaltic sequence is: 011001 101 100 110 010  and the second, different peristaltic sequence is:100 110 010 011 001 101 with “0” being a logic value corresponding to afirst one of open or close of a compartment, “1” being a logic valuecorresponding to a second, different one of open or close of acompartment and each of the phases having the values for respectivelythe input element, the pump element and the output element.
 19. Themicro pump of claim 1 wherein the plurality of micro pump elementsarranged in the series connected configuration, with the outlets of thefirst micro pump element connected to the inlets of the immediatelyadjacent one of the plurality of micro pump elements, and with inlets ofa second micro pump element connected to the outlets of the intermediatemicro pump element, with outlets of the second micro pump elementproviding outlets of the micro pump.
 20. The micro pump of claim 1wherein the plurality of micro pump elements is a first plurality ofmicro pump elements, and includes a second plurality of intermediatemicro pump elements, with the first plurality of micro pump elementsarranged in the series connected configuration, with the outlets of thefirst micro pump element coupled to the inlets of a first one of thesecond plurality of intermediate micro pump elements, and with theinlets of a second micro pump element connected to the outlets of a lastone of the second plurality of intermediate micro pump elements, withthe outlets of the second micro pump element providing outlets of themicro pump.
 21. The micro pump of claim 1 wherein the plurality of micropump elements includes an input element, a second plurality of pumpelements, and an output element.
 22. The micro pump of claim 21 whereinthe first plurality of micro pump elements are modularized micro pumpelements and each of the first plurality of micro pump elements includesa pair of end caps that together with the walls of the pump body formedthe chamber.
 23. A method comprises: connecting a plurality ofvalve-less micro pump elements in a series configuration with outlets ofa first one of the plurality of micro pump elements being fluidlyconnected to inlets of an immediately adjacent one of the plurality ofmicro pump elements; driving each the micro pump elements according to afirst peristaltic sequence in a first mode of operation, with the firstone of the plurality of micro pump elements having a port that is aninlet port of the series configuration, and a last one of the pluralityof micro pump elements having a port that is an outlet port of theseries configuration; and dynamically changing functions of the inputport and output port of the series configuration, by driving the micropump elements according to a second, different peristaltic sequence fora second, different mode of operation, with the port of the first one ofthe plurality of micro pump being the outlet port of the seriesconfiguration, and the port of the last one of the plurality of micropump elements being the inlet port of the series configuration.
 24. Themethod of claim 23 wherein the first and second peristaltic sequenceseach have six phases and each of the micro pump elements has pluralcompartments and for the plurality of micro pump elements consistingessentially of an input element, a pump element and an output element,respectively, the first peristaltic sequence is: 011 001 101 100 110 010and the second, different peristaltic sequence is: 100 110 010 011 001101 with “0” being a logic value corresponding to a first one of open orclose of a compartment, “1” being a logic value corresponding to asecond, different one of open or close of a compartment and each of thephases having the values for respectively the input element, the pumpelement and the output element.